OVERHAUL MANUAL FOR ~ : 650ce NIT CONSTRUCTION ‘TRIUMPH MOTORCYCLE ENGINES SINCE 1963 Weitter®y Thomas G. Gunn, Jr. ‘The Triumph Corporation ? a Baltimore, Maryland Novenber 20, 19672 INTRODUCTION This manual is intended to be a guide for the repair of all unit construction 650cc Triumph engines. Tt is recommended that the procedures outlined here be followed exactly until they becone a matter of routine. Over 100 mechanics of varying experience have used this manual to assemble and disassemble their own engines at our TRI-COR Mechanics Training Center. Based on this experience one comment seems necessary. Tt has been demonstrated time and again that if these directions are followed exactly word for word, the work will be correct and progress smoothly. Deviations from the methods outlined here will only result in outright errors or lost time.. Instructions for Dismantling the "BY Range 650cc Unit Construction Motorcycle Engine fe NOTE: Before commencing any work on an engine check the engine number and review 650ce Service Bulletins. Also check the engine change list in this bulletin for engine changes. Be sure you have the correct parts book for this engine number. Tt is most important to imow exactly what model engine you are dealing with! Tilustrations and a briefer explanation of procedures can be found in the 650ce ‘Triumph Workshop Manval CD11, Use the latest blue and white covered edition from engine #001394 for the most complete information on "B" Range Twins. Parts to be replaced or repaired should be written down as the engine is dis- assembled. When checking all parts, refer to the specification table in CDLi2 for proper specifications. TRIUMPH TOOLS NEEDED FOR COMPLETE OVEREAUL Dis-Agsonbt STISE’ Vale spring compressor (or equivalent) 2151 — Crankease parting tool 2121 Crankshaft pinion puller 289 Carshaft gear puller and installer DIS Clutch Holder (or equivalent made from welding or bolting T1362 and 11363 together) op222 Clutch aub puller DYGLT © Breaker point can extractor D496 Primary chain tensioner ey CD7__ Engine Locking tool aa P311TR Universal, puller CD22 Wrist pin drift Special wrench as per Service Bulletin 65/h for speedo cable nut if applicable. Inpact driver (often useful for loosening stubborn screws) cps22 Engine stand While Apart CD73 Layshaft needle bearing drift CDi © Wrist pin bush tool ChL21 Cylinder head holder 216 Valve guide punch 2223 Tappet guide block punch CDus6 = Ignition timing kit DA86T Camshaft oil seal guide 289 Camshaft gear puller and installer CDiso Clutch holder (cr equivalent made from welding or bolting 11362 and 11363 together) Du96. Primary chain tensioner CD47 Engine locking tool 233, Electrical circuit tester : Donen Wo indiostor 5 COLL Exhaust pipe adaptor wrench i) CD22 Wrist pin drigt a D3 Timing disc D123. Timing disc adaptor 1138 Valve spring compressor or equivalent Continued.